Device, system and methods for automatic development and optimization of positioning paths for multi-axis numerically controlled machining

ABSTRACT

Optimized positioning paths for multi-axis CNC machining can be generated based on the machine tool kinematics, machine axes travel limits, machine axis velocity and acceleration limits, and machine positioning methodologies. Machine axes travel limits and machine positioning methodologies are incorporated in order to ensure that the developed positioning paths do not violate machine axes travel limitations. Multi-axis positioning paths are developed to avoid collisions with dynamically changing in-process stock and other surroundings, including fixtures and both moving and non-moving components of the machine. Positioning tool path customizations give the user the flexibility to apply safety based constraints to the automatically generated tool paths. The disclosed automatic positioning path planning and optimization methods are used to develop a process for part manufacturing using CNC machining in order to reduce the manufacturing cycle time.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of a pending U.S. applicationSer. No. 13/957,949, filed Aug. 2, 2013, the disclosure of which ishereby incorporated by reference.

TECHNICAL FIELD

The current description relates to device, system and methods ofgenerating a control program for a multi-axis numerically controlled(NC) machine that automatically determines and minimizes or reducespositioning paths of a tool while avoiding tool or workpiece collision.

BACKGROUND

Numerical Control (NC) is a method of automatically operating a machinetool based on code letters, discrete numerical values, and specialcharacters. A Computer Numerical Control (CNC) machine tool is an NCmachine tool that is controlled by computers. CNC machine tools are usedto machine a workpiece to a finished shape by providing a relativemotion between the workpiece and the cutting tool. This relative motioncould be provided differently for various operations either by holdingthe workpiece stationary and moving the cutting tool, as in drilling, orby holding the cutting tool stationary and rotating the workpiece, as inturning.

A CNC machine tool is equipped with different axes of motion in order toprovide the required relative motion between the cutting tool and theworkpiece. Each of these axes has a driving device that might be a dcmotor, a hydraulic actuator, or a stepper motor.

FIG. 1 illustrates a multi-axis CNC machine 100. The machine includes acutting or machining tool 102 that can be moved relative to a workpiece118 along a plurality of different axes. As depicted in FIG. 1, themachining tool can be moved along three linear and orthogonal axesnamely the X axis 104, the Y axis 106 and the Z axis 108. Althoughdepicted as being orthogonal, it is possible that the machine tool canbe moved along a plurality of non-orthogonal axes. Additionally themachining tool 102 may rotate about one or more axes. The rotation isdepicted as being about the A axis 110, the B axis 112 and the C axis114. The A, B and C axes are depicted as being parallel with the X, Yand Z axes however, the axes do not need to be parallel. The workpiece118 is positioned on a machine table 116 in a known location allowingtranslation of the workpiece coordinates Xw 120, Yw 122, Zw 124 to themachine coordinates to allow machining of the workpiece. Although themovement of the machining tool 102 is depicted as occurring at the tool102 itself, it is noted that the motion is relative to the workpiece,and as such, motion of the workpiece or tool, or a combination thereofcan produce the same results. For example, the tool 102 may rotate aboutthe A, B and C axis and travel along the Z-axis while the table 116moves the workpiece in the X and Y axis. Multi-axis machines generallyallow movement about the X, Y and Z axis and one or more, and typically2, of the rotary axes A, B, and C. The movement between the tool and theworkpiece may be provided by movement of the tool head and/or theworkpiece or a platform the workpiece is affixed to.

CAD/CAM software can be used to specify the movement of a tool relativeto the workpiece required to produce a part from a workpiece. TheCAD/CAM software produces a plurality of tool paths that include cuttingpaths, which are paths in which the tool is in contact with theworkpiece in order to remove material to form the part, and positioningpaths, which position the tool to or from cutting paths withoutcontacting objects in the machining scene. The objects of the machiningscene may include the workpiece itself, fixtures securing the workpieceas well as portions of the machine or any other objects that the toolmay collide with. Typically positioning paths are traversed by rapidmotions that use the maximum velocity of the machine axes or a highvelocity.

FIG. 2A depicts an initial configuration of a cutting tool relative to aworkpiece. FIG. 2B depicts cutting and positioning paths for producing apart from the workpiece. A tool 204 is at an initial position relativeto the workpiece 202 as depicted in FIG. 2A. As depicted in FIG. 2B, thetool 204 moves along a positioning path A 206 to a start position 208 ofa cutting path. The cutting path B 210 moves the tool to the endlocation 212 of the cutting path B which causes the removal of material240. The tool is then repositioned to the start position 230 of the nextcutting path by positioning path C 218. The positioning path C comprises3 movements 220, 224, 228. First, the tool is retracted to a position222 on or above a clearance plane 216. Next the tool is moved to aposition 226 above the start position 230 of the next cutting path.Finally the tool is plunged 228 to the start position 230. The tool ismoved along the cutting path D 232 from the start position 230 to theend position 234 and then moved along the positioning path E 236.Positioning path again retracts the tool to the position 238 above theclearance plane 216.

FIG. 3 depicts the process of designing and producing a part on a CNCmachine. In order to machine a part from a workpiece, the part isdesigned in a computer aided design (CAD) application 302 and neutralmachining instructions can be developed in a computer aidedmanufacturing (CAM) application 302. The neutral machining instructionsspecify movement of the tool or tools as a plurality of cutterlocations. The CAM application generates tool paths that specify themovement of a tool relative to the workpiece. The tool paths includecutting paths, in which the tool is moved relative to the workpiece andis in contact with the workpiece, and non-cutting or positioning paths,in which the tool is positioned from one location to another withoutcontacting the workpiece or other components. As depicted the CAD/CAMapplication 302 may output the tool paths as a cutter location data (CLData) 304. The CL Data 304 specifies the tool location, and othermachining characteristics such as feed rate, positioning speed, cuttingspeed, etc, in a manner that can be subsequently translated into machinespecific instructions. The CL Data 304 comprises one or more cuttingpaths 306, 310, 314 each of which comprises a start configuration of thetool and an end configuration of the tool. The tool is moved betweencutting paths by respective positioning paths 308, 312. Positioningpaths may be developed in the CAD/CAM application 302 by providing auser-specified clearance plane that is defined relative to the workpiececoordinates and geometry. A similar approach is for the user to defineone or more safety zones. In either case, the CAM application retractsthe tool to the safe zone, or to the clearance plane and then moveswithin the clearance plane or safety zone to approach the next cuttinglocation, and finally moves to the start of the next cutting location.Additionally or alternatively, the CAD/CAM application may allow theuser to specify the positioning paths manually by defining movementsalong different directions. Regardless of how the positioning paths aregenerated, they can require considerable user interaction to producesafe positioning paths for a particular machine.

In order to machine a part according to the specified CL Data, the CLData must be transformed into machine-dependent code for the particularmachine being used to machine the part. This translation is performed byan NC post-processor 316. The post-processor 316 receives controllersettings 318, and a machine selection 320 specifying a particularmachine that will be used to machine the part. The post-processortransforms the CL Data 304 into a machine specific NC program 324. Thepost-processor 316 generates the NC program using information about thekinematics of the selected machine 322, that is information about howthe selected machine provides the relative movement between the tool andthe workpiece. As depicted the NC program 324 may be executed by asimulation of the CNC machine 326 in order to verify that thepositioning paths and cutting paths are valid, that is there are nocollisions between objects in the machining scene and machine travellimits are respected. The simulation of the CNC machine 326 may alsoverify the syntax of the NC program to ensure it uses proper syntax. Ifthe NC program comprises valid positioning paths and cutting paths 330,the NC program can be executed on the CNC machine 332 to produce thepart.

The NC program 324 is typically first run on a CNC machine simulator 326to ensure that the NC program 324 does not cause collisions, or violatemachine travel limits. Non-cutting positioning paths generated by CAMapplications for multi-axis machining can be unsafe and inefficient.This is mainly because CAM applications ignore the particular machinecharacteristics of the CNC machine that will be used to produce thepart. The machine characteristics may include, for example, machine toolkinematics, axis travel velocities, axis acceleration, travellimitations, positioning methodologies, and workpiece setup in thegeneration of positioning tool paths. Accordingly, invalid positioningpaths or cutting paths 328 must be adjusted in the CAM application usingtrial and error. Once the user has adjusted the positioning paths, theNC program can be generated and tested again. This process of trial anderror must be repeated until successful positioning paths are defined inthe CAM application. The trial and error process for generatingpositioning paths for a particular CNC machine can require considerableuser interaction.

The trial and error by a user required to specify safe positioning pathsfor a specific machine is undesirable. Further, once an NC program isgenerated with safe positioning paths, it is machine specific and thetime consuming trial and error process needs to be carried out again ifthe part is to be machined on a different machine having differentmachine kinematics. Further still, the positioning paths developed bythe trial and error process may not be the optimal positioning pathsresulting in longer machining time.

An alternative to developing positioning paths is desirable. In thisregard, it may be beneficial to automatically develop positioning pathswithout substantial user interaction as an alternative to the currenttechniques for developing positioning paths.

SUMMARY

In accordance with the present disclosure there is provided a method forgenerating positioning path data for a computer numerically controlled(CNC) machine, the method comprising determining a start configurationand a goal configuration of a tool in a machine configuration space;identifying respective regions surrounding one or more relevant featuresof a machining scene in the machine configuration space for sampling ofpossible configurations; determining a plurality of possibleconfigurations from each of the identified one or more regions in themachine configuration space; determining a positioning path from, theplurality of possible configurations that connects the startconfiguration to the goal configuration; determining if the determinedpositioning path is valid using a simulation of the CNC machine; andgenerating positioning path data for moving the tool of the CNC machinealong the determined positioning path if the positioning path isdetermined to be valid.

In a further embodiment, the method may further comprise determining aninitial positioning path that connects the start configuration to thegoal configuration without violating machining constraints; and whereinthe positioning path determined from the plurality of possibleconfigurations is determined to have a lower associated time-cost than atime-cost of the initial positioning path.

In a further embodiment, determining the initial positioning path maycomprise: determining a first intermediary configuration by translatingthe start configuration a first distance in a first preferred direction;determining a second intermediary configuration by translating the goalconfiguration a second distance in a second preferred direction;connecting the first intermediary configuration to the secondintermediary configuration; and optimizing a travel time of thepositioning path by reducing the first distance and second distancewithout causing the initial positioning path to violate the machiningconstraints.

In a further embodiment, the first distance and the second distance thatare reduced are the same distances.

In a further embodiment, the method may further comprise: determining ifthe initial positioning path violates the machining constraints; and ifthe initial positioning path violates the machining constraints:translating the start configurations and the goal configurations inrespective other preferred directions; and connecting the firstintermediary configuration to the second intermediary configuration.

In a further embodiment, the first preferred direction, the secondpreferred direction, and the other preferred directions are selectedfrom one or more of: a direction based on a tool axis orientation of thestart configuration; a direction based on a tool axis orientation of thegoal configuration; and a direction based on an axis of control of theCNC machine.

In a further embodiment, a time-cost associated with a path isdetermined by simulating movement of the CNC machine.

In a further embodiment, simulating movement of the CNC machinecomprises simulating acceleration limits on machine axes whendetermining the time-cost.

In a further embodiment, a time-cost associated with a path isdetermined using a length of the path and known travel velocities alongmachine axes.

In a further embodiment, determining if a path violates machiningconstraints comprises using a simulator of the CNC machine to determineif the path is valid or not.

In a further embodiment, determining the start configuration and thegoal configuration in the machine configuration space comprises:receiving a start configuration and goal configuration in a workpiecespace; and transforming the start and goal configurations in theworkpiece space to the start and goal configurations in the machineconfiguration space.

In a further embodiment, determining the start configuration and thegoal configuration in the machine configuration space comprisesadjusting at least one of the start configuration and the goalconfiguration based on one or more user preferences.

In a further embodiment, adjusting at least one of the startconfiguration and the goal configuration comprises, for the respectiveconfiguration being adjusted: translating the respective configurationin order to move the tool of the CNC machine out of contact with thework piece; and adding the translation of the respective configurationto the positioning path data.

In a further embodiment, the translation of the respective configurationis determined by: sampling a plurality of sphere locations from asurface of a sphere centered around the respective configuration; andattempting to identify a sampled sphere location that does not cause thetool to be in contact with the workpiece when the tool is translated tothe sampled sphere location; and determining that the path translatingthe tool to the sampled sphere location is valid.

In a further embodiment, the method may comprise: expanding a radius ofthe sphere and sampling additional sphere locations if a sample spherelocation that does not cause the tool to be in contact with theworkpiece is not identified, wherein sphere locations on a smallerradius sphere minimize the translation of the respective configurations;and attempting to identify the sphere location that does not cause thetool to be in contact with the workpiece from the additional spherelocations.

In a further embodiment, adjusting at least one of the startconfiguration and the goal configuration comprises at least one of:adjusting the start configuration based on a user specified retractpath; adjusting the goal configuration based on a user specifiedapproach path; determining that paths adjusting the start configurationand the goal configuration are valid; and adding movements of theadjustments to the start and goal configurations to the positioning pathdata.

In a further embodiment, adjusting at least one of the startconfiguration and the goal configuration comprises: adjusting the startconfiguration to a location that accommodates an expanded tool sizeexpanded by a user specified minimum safety distance; adjusting the goalconfiguration to a location that accommodates the expanded tool size;determining that paths adjusting the start configuration and the goalconfiguration are valid; adding movements of the adjustments to thestart and goal configurations to the positioning path data; andadjusting the simulation of the CNC machine to use an offset tool withan offset based on the user specified minimum safety distance whendetermining if the positioning path is valid.

In a further embodiment, adjusting each of the start configuration andthe goal configuration to accommodate the expanded tool size comprises:sampling a plurality of sphere locations from a surface of a spherecentered around the respective configuration and having a radius atleast equal to the user specified minimum safety distance; andattempting to identify a sampled sphere location that does not cause theexpanded tool to be in contact with the workpiece when the expanded toolis translated to the sampled sphere location.

In a further embodiment, the method may further comprise expanding aradius of the sphere and sampling additional sphere locations if asample sphere location that does not cause the expanded tool to be incontact with the workpiece is not identified, wherein sphere locationson a smaller radius sphere minimize the translation of the respectiveconfigurations; and attempting to identify the sphere location that doesnot cause the expanded tool to be in contact with the workpiece from theadditional sphere locations.

In a further embodiment, the relevant features of the machining scene inthe machine configuration space comprise one or more of: knownconfigurations along a positioning path; and respective bounding boxesof one or more objects in the machining scene.

In a further embodiment, the method may further comprise: dividingcontrol axes of the CNC machine into spans based on maximum and minimumtravel values for the respective control axis and the start and goalconfigurations; determining if each of the spans has been sampled by theplurality of possible configurations from the identified regions; andcollecting a plurality of additional possible configurations fromoutside of the identified regions to provide samples of possibleconfigurations from each of the spans.

In a further embodiment, a minimum sampling resolution is defined foreach of the control axes of the CNC machine, the minimum samplingresolution defining the minimum distance between samples of therespective control axis.

In a further embodiment, the method may further comprise removingpossible configurations from the plurality of possible configurations ifthey are within an excluded region in the machine configuration space.

In a further embodiment, determining the positioning path comprises:treating the plurality of possible configurations, the startconfiguration and the goal configuration as a graph; and searching thegraph for a path from the start configuration to the goal configuration.

In a further embodiment, the graph is searched using a heuristics basedsearch technique which finds a lowest cost path that is less than anupper bound through the graph if such a path exists.

In a further embodiment, when the path through the graph exists, thepath is used as the positioning path, and wherein determining if thepositioning path is valid comprises: receiving an indication from thesimulation of the CNC machine that the positioning path is valid or not,the indication comprising an indication of a configuration that causedthe invalidity of the positioning path when the positioning path isinvalid; determining a segment of the graph associated with theindicated configuration that caused the invalidity of the positioningpath; and removing the determined segment from the graph.

In a further embodiment, the method may further comprise: determining ifthe search of the graph has exhausted all possible paths when thepositioning path is not valid; and searching the graph again, when thesearch of the graph is not exhausted, for a path from the startconfiguration to the goal configuration.

In a further embodiment, the method may further comprise: collecting afurther plurality of possible configurations from the machineconfiguration space when no path through the graph that has anassociated cost less than the upper bound is found or when the search ofthe graph is exhausted; and treating the plurality of possibleconfigurations, the start configuration, the goal configuration and thefurther plurality of possible configurations as the graph; and searchingthe graph for a path from the start configuration to the goalconfiguration.

In a further embodiment, searching the graph comprises using an A*search technique.

In a further embodiment, wherein the A* search uses: a path travel timeprovided by the simulation of the CNC machine as a cost of a currentpath from the start configuration to a current configuration node of thegraph; and a travel time provided by the simulation of the CNC machineas a cost between the current configuration node to the goalconfiguration.

In a further embodiment, the simulation of the CNC machine incorporatesmachine characteristics into simulating machining on the CNC machine,the machine characteristics comprising one or more of: machinekinematics; velocity limits; acceleration limits; travel limitations foreach machine axis; positioning methodologies; workpiece setup; locationof machine components or fixtures; and location of holding devices.

In a further embodiment, the simulation of the CNC machine simulatesdynamically changing workpieces.

In accordance with the present disclosure there is further provided acomputing device for generating positioning path data for a computernumerically controlled (CNC) machine, the system comprising a processorfor executing instructions; and a memory for storing instructions, whichwhen executed by the processor configures the system to provide a methodfor generating positioning path data for a computer numericallycontrolled (CNC) machine, the method comprising determining a startconfiguration and a goal configuration of a tool in a machineconfiguration space; identifying respective regions surrounding one ormore relevant features of a machining scene in the machine configurationspace for sampling of possible configurations; determining a pluralityof possible configurations from each of the identified one or moreregions in the machine configuration space; determining a positioningpath from the plurality of possible configurations that connects thestart configuration to the goal configuration; determining if thedetermined positioning path is valid using a simulation of the CNCmachine; and generating positioning path data for moving the tool of theCNC machine along the determined positioning path if the positioningpath is determined to be valid.

In accordance with the present disclosure there is further provided asystem for machining a part, the system comprising a computing devicefor generating positioning path data for a computer numericallycontrolled (CNC) machine, the system comprising a processor forexecuting instructions; and a memory for storing instructions, whichwhen executed by the processor configures the system to provide a methodfor generating positioning path data for a computer numericallycontrolled (CNC) machine, the method comprising determining a startconfiguration and a goal configuration of a tool in a machineconfiguration space; identifying respective regions surrounding one ormore relevant features of a machining scene in the machine configurationspace for sampling of possible configurations; determining a pluralityof possible configurations from each of the identified one or moreregions in the machine configuration space; determining a positioningpath from the plurality of possible configurations that connects thestart configuration to the goal configuration; determining if thedetermined positioning path is valid using a simulation of the CNCmachine; and generating positioning path data for moving the tool of theCNC machine along the determined positioning path if the positioningpath is determined to be valid; and a Computer Numerically Controlled(CNC) machine for receiving the NC program and machining a part from aworkpiece in accordance with the NC program.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present disclosure will becomeapparent from the following detailed description, taken in combinationwith the appended drawings, in which:

FIG. 1 illustrates a multi-axis CNC machine;

FIG. 2A depicts an initial configuration of a cutting tool relative to aworkpiece;

FIG. 2B depicts cutting and positioning paths for producing a part fromthe workpiece;

FIG. 3 depicts the process of designing and producing a part on a CNCmachine;

FIG. 4A depicts a positioning path in workpiece coordinates;

FIG. 4B depicts the positioning path of 4A accounting for machinekinematics;

FIG. 5 depicts a process of designing and producing a part on a CNCmachine using automatically generated positioning paths;

FIG. 6 depicts a method for designing and producing a part on a CNCmachine using automatically generated positioning paths;

FIG. 7 depicts a method of generating an NC program for machining apart;

FIG. 8 depicts a method of automatically generating positioning paths;

FIG. 9 depicts a method for customizing a positioning path;

FIGS. 10A, 10B, 10C, 10D depict positioning path customization;

FIG. 11 depicts an initial positioning path;

FIG. 12 depicts a further method of developing an NC program;

FIG. 13 depicts sampling of machine space for developing a positioningpath;

FIG. 14 depicts developing the positioning path;

FIG. 15 depicts method for generating positioning paths; and

FIG. 16 depicts a system for machining a part.

DETAILED DESCRIPTION

Computer Numerically Controlled (CNC) machines allow a part to bemachined from a workpiece in accordance with specific instructions. Apart can be designed in a 3D modeling application, often referred to asComputer Aided Design (CAD) software. Computer Aided Manufacturingsoftware can take a 3D model and produce code or instructions forgenerating the part. The code generated by CAM software specifies themovement of a tool in relation to a workpiece, in the coordinates of theworkpiece. In order to machine a part, the tool locations specified inthe workpiece coordinates need to be converted into tool locations inmachine coordinates. At its most basic, this may be viewed as atranslation of the workpiece coordinates based on the physical positionof the workpiece in the CNC machine. However, in multi-axis machinesthat allow rotational movement as well as linear movement, theconversion may be more complex since the kinematics of the CNC machinemay result in non-linear movement of the tool, while the generation ofthe tool paths in the CAM software assumes linear movement between toolconfigurations.

FIG. 4A depicts a positioning path in workpiece coordinates. Thepositioning path comprises a start configuration of the tool 404relative to the workpiece 402 and a goal configuration of the tool 406.The configuration includes both the position and orientation of thetool. In workpiece coordinates, which do not consider how the toolmovement is actually implemented, the positioning path between the startand goal configuration is a linear path 408. However, if the positioningpath is implemented on a CNC machine, the actual path the tool traversesbetween the start and goal orientations may not be linear. FIG. 4Bdepicts the positioning path of 4A accounting for machine kinematics. Asdepicted, the tool moves between a start configuration 414,corresponding to configuration 404, to a goal configuration 416,corresponding to goal configuration 406. However, the combination of thelinear and rotational movement between the two configurations results ina non linear path 418, which may result in unintended movement of thetool and possible collisions with the workpiece or other objects in themachining scene.

Machine kinematics affect both cutting paths and positioning paths.However, cutting paths that involve both a change in the orientation andlocation of the tool are typically very short, and as such thekinematics do not change the desired tool path by a large amount. Incontrast, positioning paths may change orientation and location over along distance and as such the deviation of the tool path may be greater.

The generation of safe, or valid, positioning paths is described furtherherein. An unsafe, or invalid, path may be a path that violates aconstraint. For example, a positioning path may be invalid if the toolcontacts the objects in a machining scene such as the workpiece,fixtures, setups, holding devices or a structure of the CNC machine.Constraints may result from the CNC machine. For example, tool paths maybe invalid if they move more than the maximum travel amount for an axis,or contact parts of the machine. Constraints may be dependent upon thepart being machined, for example, positioning paths may be invalid ifthey contact part of the workpiece. Further, constraints may be userspecified, for example, a path may be invalid if a tool comes within adefined safe distance of the workpiece when travelling at a rapid ratesuch as during positioning movements. As described further herein, validpositioning paths that conform to machine constraints can beautomatically generated based on machine characteristics such as themachine kinematics, machine velocity and acceleration, and machinepositioning methodology. Since the positioning paths are automaticallygenerated taking into account the machine characteristics, it ispossible to generate the positioning paths without requiring the user toperform any trial and error.

As described further herein, automatically generating the positioningpath, taking in to account the machine kinematics may provide variouspossible advantages, in addition to providing an alternative techniquefor generating positioning paths. The automatic generation of thepositioning paths for multi-axis CNC machines can reduce the productmanufacturing cycle time by eliminating the process of trial and errorto adjust and verify multi-axis positioning paths in the CAM applicationas well as minimizing the unproductive time of the positioning pathsbased on the machine tool kinematics, machine axes travel limits,machine axis velocity and acceleration limits, and machine positioningmethodologies. Further, by automatically generating safe multi-axispositioning paths, which are collision-free based on the actual machinetool kinematics, dynamically changing in-process stock, workpiecesetups/fixtures, and machining environment, it is possible to generatemachine dependent NC programs for different machines without requiringadditional user effort. Accordingly, the machining of a part can beeasily changed to different machine types without requiring the user toperform the trial and error process again. Further, the automaticgeneration of positioning paths can facilitate maximizing partaccessibility by searching the machine configuration space and takingfull advantage of the CNC machine's work envelope to accommodatemulti-axis motions. By automatically generating safe multi-axispositioning paths, the user does not need to define clearance planes orsafety zones.

The current disclosure presents devices, system and methods forautomatic positioning (i.e. non-cutting) path development andoptimization. Automatic path planning for positioning paths is performedto generate optimal safe paths while minimizing non-cutting time, whichis unproductive. The positioning paths are developed based on machinetool kinematics, machine axes travel limits, machine axis velocity andacceleration limits, and machine positioning methodologies. Thedeveloped positioning paths do not violate machine axes travellimitations and do not cause collisions with the dynamically changingin-process stock of the workpiece and all other surroundings, includingfixtures and the moving and non-moving components of the machine. Thesemethods do not require clearance planes or geometric safety zones to bedefined by the user. The present methods can apply a safe positioningstrategy by respecting a user-specified minimum distance between thetool and other objects in the scene. A predefined retract and approachstrategy can also be respected at the start and end of the positioningsequence, where the tool is close or in-contact with the workpiece.Moreover, the contact between the tool and in-process stock can beanalyzed to minimize non-cutting time in proximity between tooling andin-process stock so as to eliminate dwells. The result of theoptimization will be safe and minimized positioning motions in themachine coordinate system that can be directly run on the CNC machine.

FIG. 5 depicts a process of designing and producing a part on a CNCmachine using automatically generated positioning paths. The processinvolves generating a 3D model of a part to be manufactured anddescribes cutter location data (CL Data) for producing the part from aworkpiece using CAD/CAM software 502. The CL Data 504 only needs tospecify the cutting paths 506, 508, 510 for producing the part. It doesnot require the user to specify positioning paths. Although depicted asnot having any positioning paths, the CL Data may include positioningpaths, in which case they are identified and removed or ignored sincethe positioning paths will be automatically generated.

The CL Data 504 is processed by a numerically controlled (NC)post-processor. The post-processor 512 receives controller settings 514and an indication of the CNC machine 516 the part will be produced on.In addition to generating NC data for the cutting paths, which may bedone using known existing techniques, the post-processing also developspositioning paths 518 for moving the tool between cutting paths. Thepositioning path development 518 uses the machine kinematics 520 and asimulator 522 of the CNC machine to develop the positioning paths. Thepost-processor 512 receives the machine independent CL Data andgenerates the machine dependent NC program 524 for producing the part onthe selected machine. The NC program 524 may be run on a CNC machinesimulator 526 to ensure the desired performance is achieved. Since thepositioning paths have been automatically generated and optimized takinginto account the machine characteristics, the positioning paths will bevalid. However, it is possible that the cutting paths are invalid, andas such may require adjustment in the CAD/CAM software prior to runningthe NC program on the physical CNC machine 532. The CNC machinesimulators 522, 526 may be provided by the same or separate components.The valid positioning paths and cutting paths 530 may be run by the CNCmachine 532 to produce the part.

The post-processing 512 can transform the machine independent CL Data504 to the machine dependent NC program 524 with little userinteraction. The user is only required to specify controller settings aswell as select the particular machine the part will be produced on.Accordingly, machining of parts can be easily moved between differentmachines to meet shop requirements. Further, additional CNC machines canbe added to a shop without concern of the effort required to generate NCprograms of existing parts for the new machine.

FIG. 6 depicts a method for designing and producing a part on a CNCmachine using automatically generated positioning paths. The method 600begins with generating a 3D model of the part to be machined (602). Themodel may be developed in any suitable software application, typicallyreferred to as CAD software. The 3D model is used to generate cuttingpaths (604) which are specified as cutter locations (CL Data). Thecutting paths may be generated by CAM software. The CAD and CAM softwarefunctionality may be incorporated into a single software application.The CL Data produced by the CAM software is processed in order toconvert the CL data into specific code or instructions for controlling aCNC machine to produce the part, which is outputted as NC data (606).The NC data may form an NC program. The processing of the CL Dataconverts the cutting paths into specific machine instructions to movethe tool along the required cutting paths. Additionally, the processingdetermines positioning paths (608) and simulates the positioning paths(610) for moving the tool between the cutting paths to verify that thepath is valid. Once the CL Data is converted into NC data, for both thespecified cutting paths and developed optimized positioning paths, theNC data may be run on a simulator of the CNC machine (612), for example,to verify that the NC Data performs as desired. The method determines ifthe NC data is acceptable based on the simulator results (614). Althoughthe results may be valid, that is the positioning paths do not causecollisions and do not violate machine travel limits or otherconstraints, they may still be considered unacceptable. For example, auser may determine that a cutting path does not produce the desiredresult. If the NC data is acceptable (Yes at 614), that is it producesthe desired results without violating any constraints, the NC data maybe run on the CNC machine to control the CNC machine in order to producethe part (616). If the NC data is not acceptable (No at 614), that is itdoes not produce the desired results or violates a constraint, themethod may return to generating the cutting paths (604) or the modelitself (602) to produce the desired results.

FIG. 7 depicts a method of generating an NC program for machining apart. As depicted, the method 700 has 3 broad sections. The first 702,generates NC data for moving the tool from an initial or homeconfiguration to the start configuration of the first cutting path, aswell as the NC data for the first cutting path. The second section 704generates positioning and cutting path NC data for the remaining cuttingpaths. Finally 706, the method generates the NC data for moving the toolfrom the last cutting orientation to a finishing orientation, which maybe the home orientation. The method 700 receives CL Data specifying oneor more cutting paths (708). If the received CL Data also specifiespositioning paths, they may be removed or ignored. A positioning path isdetermined for safely moving from an initial machine configuration to astart configuration of the first cutting path (710). Once thepositioning path is determined, the NC data of the positioning path isadded to the NC program (712). The NC data for the cutting path isdetermined and added to the NC program (714). The method determines ifthere are additional cutting paths (716) and if there are (Yes at 716)the next cutting path is retrieved (718). A positioning path for movingfrom the end configuration of the previous cutting path to the startconfiguration of the retrieved cutting path is determined (720). The NCdata of the positioning path is determined and appended to the NCprogram (722). The NC data for the current cutting path is determinedand appended to the NC program (724), and again it is determined ifthere are further cutting paths to process (716). If there are no morecutting paths (No at 716), the method determines a positioning path tomove the tool from the end configuration of the last cutting path to atermination machine configuration (726), which may be the same as theinitial machine configuration. The NC data for the last positioning pathis appended to the NC program (728) and the NC program is returned orstored (730).

FIG. 8 depicts automatically developing positioning paths. Positioningpath development and optimization 802 functionality generates optimizedand valid positioning paths between a start configuration of the machineand a goal configuration of the machine. As shown in FIG. 8, thepositioning path development and optimization functionality 802 relieson machine simulation functionality 804. The simulation functionality804 is used by the path development functionality 802 to simulate toolmotion based on the machine tool kinematics and positioningmethodologies, such as tool tip programming and etc. The machinesimulation functionality 804 includes functionality to perform acollision test 812, functionality to perform a travel test 814, andfunctionality for performing a travelling time computation 816. The useof the simulation functionality 804 allows the path development processto remain generic and independent of the machine characteristics.Machine simulation functionality 804 can be provided by any of availableproducts or components that provide functionality of collision test 812,travel test 814, and travelling time computation 816. The simulationshould be able to precisely simulate a motion in machine space based onmachine kinematics, machine velocity and acceleration, and machinepositioning methodology in order to check if positioning paths violatemachine axis travel limitations and causes collisions with dynamicallychanging in process stock of the workpiece and all other surroundings,including fixtures and the moving and non-moving components of themachine to provide proper test results. The path development andoptimization functionality 802 relies on simple collision test queries(i.e. yes/no queries). The positioning path development and optimizationfunctionality 802 does not require distance computation or othercomputationally expensive collision test strategies to be performed bycollision test functionality 812.

As depicted, the automatic kinematic-based development and optimizationof positioning paths 802 involves three major stages. The input topositioning path development functionality 802 comprises an initialstart configuration of the tool and goal configuration of the tool,along with a selection of the machine kinematics and differentcontroller settings. The position path development and optimizationutilizes path customization functionality 806 to initially customizestart and goal configurations according to user preferences. Initialpath planning by directional search and minimization functionality 808is used to provide, or attempt to provide, an initial positioning pathbetween the customized start and goal configurations. Deterministicsampling based path planning functionality 810 uses a sampling basedapproach to optimize the positioning path between the start and goalconfigurations.

Initially, the start and goal configurations are provided to pathcustomization functionality 806. To accommodate user requestedcustomization options, positioning paths are first planned at theinitial start and goal configurations. These paths are then saved andtheir end configurations become the new start and goal configurations.Accordingly, the path customization functionality 806 adjusts the startand goal configurations and the adjusted configurations are used insubsequent stages of the path development functionality.

The initial path planning functionality 808 uses a directional searchmethod to find a suboptimal solution for the path planning between thestart and goal configurations, which may have been adjusted by the pathcustomizations functionality 806. The initial path planningfunctionality attempts to quickly find an initial solution to the pathplanning by searching in the machine space in some potentially gooddirections. The result from this stage is a positioning path between thestart and goal configurations; however, this path may not be the best.Additionally, the initial path planning functionality may fail to find avalid path between the start and goal configurations.

The adjusted start and goal configurations and the solution path foundby the initial path planning functionality 808 are provided to thesampling based path planning functionality 810.

An anytime strategic and deterministic sampling-based search techniqueis used to attempt to find a better positioning path between the startand goal configurations. The initial path may be used by thedeterministic sampling based path planning functionality 810 in order toreduce the amount of time required to find a positioning path betweenthe start and goal configurations. However, the deterministic samplingbased path planning functionality 810 can still find a valid positioningpath even if no initial positioning path was found.

As depicted in FIG. 8, the positioning path functionality 802 provides atest path 818 to the machine simulation functionality 804, which maytest the path to determine if it is valid. The test path can bevalidated using the collision test functionality and the over-traveltest functionality. The machine simulation functionality may return theresult of the path validity 820 to the position path development.Although not depicted in FIG. 8, the machine simulation functionality804 may also be used to provide an amount of time a particular machinewill require to perform the test path.

FIG. 9 depicts a method for customizing a positioning path. The pathcustomization options may include three major options. The pathcustomization method 900 adjusts the start and goal configurations basedon workpiece proximity and wall detection (902). When the start and goalconfigurations are passed to proximity and wall detection, it checkswhether the tool is in contact with the in-process stock or beside awall. This is checked using a collision test to verify if the tool willcollide with the in-process stock. In the case that the tool is incontact with the in-process stock or beside a wall, a feed motion isgenerated to minimize the non-cutting time in the proximity between thetool and workpiece so as to eliminate dwells. In the wall case, it isdesirable to avoid moving along directions along which the tool mayleave unwanted dwelling marks on the final part surface. Thus, the startand goal configurations are adjusted to disengage the tool from thecontact with in-process stock along a direction that is not in touchwith the in-process stock. The path for adjusting the start and goalconfigurations path will then be outputted as a feed motion which can beused in the NC program for generating the part. The adjusted start andgoal configurations are further adjusted using retract and approachpaths based on a predefined strategy at these positions (904). Anexample can be generating a path along a user-defined direction or toolaxis direction at these positions. These paths can be outputted as rapidor feed motions based on the user request. The safety of these paths isverified by simulation before they are saved. The further adjusted startand goal positions are again adjusted based on minimum safety distance(906). The purpose for this option is designing a path that does not putthe tool closer than a minimum distance to any objects in scene. Inorder to achieve this, an offset tool having an offset distance based onthe required minimum safety distance is created and used in simulationto verify the path safety. This will cause the paths that are closer tothe objects than the minimum safety distance to be declared as unsafepaths and skipped by the path planning algorithms. However, the minimumsafety distance option needs to find a position at start and goal thataccommodates the larger offset tool before the path planning commences.

FIGS. 10A, 10B, 10C, 10D depict positioning path customizations. AG. 10Adepicts the initial start and goal configurations 1004, 1006 relative tothe workpiece 1002. As depicted, additional configurations 1008, 1010are determined in establishing a positioning path, comprising movementsbetween configurations 1012, 1014, 1016. FIG. 10B depicts adjusting thestart and goal configurations 1004, 1006. The adjustment to the startand goal configurations may be done in the same manner. A sphere,depicted as circle 1018 in FIG. 10B, with a small radius is firstlyestablished at a tool center. The sphere 1018 surface is sampled for XYZcoordinates while the tool orientation is kept constant. The samples aresearched to determine if moving the tool to the point 1020, for examplealong path 1022, does not cause the tool to be in touch with in-processstock 1002. Samples for a specific sphere radius are collected and themotion between current tool position and these samples is verified bysimulation functionality. The acceptable motion is the one along whichthe tool does not touch the in-process stock except at the current toolposition. If all motions fail, it means none of the samples on thesphere could direct the tool along a good direction with the currentsphere radius. New samples should then be collected from the sphere.Samples on the sphere can be controlled by their angles with respect tothe tool axis direction. Once all samples for a constant sphere radiushave been tested with no success, the sphere radius is increasedincrementally and the described steps are repeated to find a solution.The best solution is the one that is found by the minimum sphere radius.The result is a path 1022, 1026 with the length equivalent to the sphereradius. Alternatively, a user-determined length can also be appliedalong the best direction on the sphere.

FIG. 10C depicts adjusting the configurations 1020, 1024 to use retractand approach paths. The adjusted start and goal positions 1020, 1024 areused to develop retract and approach paths based on a predefinedstrategy at these positions. For example, the retract and approach pathscan be generated along a user-defined direction or tool axis directionat these positions. These paths can be outputted as rapid or feedmotions based on the user request. The safety of these paths is verifiedby simulation before being saved or outputted. The result from adjustingthe configurations using retract and/or approach paths will be newpositions 1028, 1032 based on the implemented retract/approach strategyat the start and goal.

As depicted in FIG. 10D the start and goal positions 1028, 1032 may thenbe adjusted in order to account for a minimum safety distance option.The minimum safety distance option designs a path that does not put thetool closer than a minimum distance to any objects in scene. In order toachieve this goal an offset tool 1036 having an offset based on theminimum safety distance is created and used in simulation to verify thepath safety. A similar type of search using a sphere as described abovewith regard to FIG. 10B may be used to adjust the start and goalconfigurations along paths 1040, 1044 in order to accommodate the largeroffset tool, however, the larger offset tool is used in order to testthe safety of the motions. The result from this algorithm will be newpositions 1038, 1042 at start and goal configurations that accommodatethe larger offset tool. Now, the path planning can be performed usingthe larger offset tool to guarantee the user requested safety.

As described above, the start and goal configurations can be adjusted toaccount for user customizations. Although described as performing all ofthe customizations, it is contemplated that one or more of thecustomizations can be applied without applying all of thecustomizations. The adjusted start and goal configurations can be usedin determining the positioning path. An initial positioning path isfirst determined and then used in determining an optimized positioningpath.

FIG. 11 depicts an initial positioning path in the machine configurationspace. It is noted that the machine configuration space depicted in FIG.11 is 2 dimensional. It will be appreciated that the machineconfiguration space will typically be of a higher dimension, such as 3,4, 5 or higher dimensions. However, the drawings are depicted in 2D inorder to facilitate the description. One of ordinary skill in the artwill readily appreciate how to apply the teachings to higher dimensions.The initial positioning path may be developed by a directional searchand minimization using the start and goal configurations in order toplan a path between them. These configurations can be the onesdetermined by user customization options as described above, or may bethe un-adjusted start and goal configurations. The path planning problemfor multi-axis machining is a multi-dimensional problem depending on thenumber of active axes on the machine. In general, solving such a problemmay become time-consuming. The initial positioning path is determined byreducing the problem dimension by a constrained search along somepredefined directions to find a suboptimal solution for the problem. Thepositioning path development strategy used here comprises threemovements of the tool in the machine space. The positioning path movesalong path 1112 to an intermediate configuration 1108, along path 1116to another intermediary configuration 1110, and finally along path 1114to the goal configuration 1106. As depicted in FIG. 11, the positioningpath 1112, 1114, 1116 do not pass through the obstacle zone 1102, whichmay be for example the in-process workpiece. All configurations in theobstacle region 1102 violate the planning requirements so they are notacceptable. In the first step in developing the initial positioningpath, an intermediary configuration 1108 is found by moving 1112 thetool along a predefined direction in machine space, such as tool axisdirection, from the start configuration 1104 without changing theorientation of the tool. In the second step, the intermediaryconfiguration 1110 is determined by moving 1114 along a predefineddirection in machine space, such as tool axis direction, from the goalconfiguration 1106.

In the third step, the intermediary configurations 1108 and 1110 areconnected 1116. Since the tool axis directions at the intermediaryconfiguration 1108 and the start configuration 1104 are the same, as arethe tool axis directions at intermediary and goal configurations 1110,1106, machine rotary values remain the same at these configurations aswell. Therefore, the distances between start and intermediaryconfigurations 1104, 1108 as well as intermediary and goalconfigurations 1110 and 1106 are Euclidian distances in machine spaceand are called ds and dg respectively. In order to plan a path betweenstart and goal configurations 1104, 1106 ds and dg must be specified. Atwo-dimensional minimization can be devised to identify ds and dg valuesthat minimize the travelling time while still generating a valid path.The problem dimension can be reduced further by an insignificantcompromise of the solution quality. It can be assumed that ds=dg=d. Theminimization can then be performed by a 1-D search method, such as thegolden section search method, to minimize the travelling time byreducing d value. The solution is a d value that minimizes thetravelling time and connects the start and goal configurations 1104 and1106 while respecting all the defined constraints. The result from the1D search is an optimized path along the predefined directions. Thispath is a local solution to the path finding problem and can be foundquickly.

Once the initial positioning path is determined, an optimized path canbe developed using a sampling based approach as described further below.A number of samples are obtained from the machine space, which are usedto build a graph of possible positioning paths between the start andgoal configurations.

FIG. 12 depicts a further method of developing an NC program. The method1200 receives CL Data for producing a component (1202), and identifiesthe cutting paths in the received CL Data (1204). For each of theidentified cutting paths (1206) a positioning path is determined to movethe tool from a current configuration to a goal configuration (1208). NCData is determined for the positioning path and the NC Data is appendedto an NC Program (1210) for generating the component. NC Data for thecutting path is appended to the NC Program (1212). Motion datadescribing the cutting and positioning paths is provided to thesimulator (1214) which uses the motion data to update the simulatedworkpiece in accordance with the cutting path. The configuration isupdated to the stop configuration of the cutting path, and the nextcutting path is processed (1216). A positioning path is determined tomove the tool from its current configuration to an end configuration(1218), such as a home configuration of the machine. NC data for thefinal positioning path is determined and appended to the NC Program(1220).

As depicted, determining the position path between a start configurationand a goal configuration may involve adjusting the start configurationbased on workpiece proximity wall detection (1222) and the goalconfiguration (1224). The start and goal configuration can beselectively adjusted independently of each other. The startconfiguration can be adjusted using a specified retract path (1226) andthe goal configuration can be adjusted using a specified approach path(1228). Again, these start and goal configurations can be selectivelyadjusted independently of each other. The start and goal configurationscan be adjusted based on minimum safe distances (1230) if required. Thestart or goal configuration may already accommodate the larger offsettool, in which case the configuration will not change; however, theconfigurations still need to be checked against the larger offset tool.When adjusting the start and goal configurations for a minimum safedistance, both the start and goal configurations must be considered sothat the larger offset tool will not contact the workpiece at either thestart or the end configurations.

Once the start and goal configurations are adjusted, an initialpositioning path is determined that moves from the adjusted startconfiguration to the goal configuration (1232). The initial positioningpath may be determined as described above. The initial positioning pathis associated with a time-cost. Time-costs of paths may be determinedusing a simulation of the machine or may be determined based onavailable information of the machine. For example, if the maximumvelocity of travel along the different machine axes is known, thetime-cost may be estimated using the velocities and distance of thepath. The simulation may provide a more accurate time-cost estimate by,for example accounting for the acceleration along the machine axes.

Once the initial positioning path is determined, an optimizedpositioning path, that is a positioning path that takes less time tocomplete, is determined. The positioning path is determined using asampling based technique. A strategic and deterministic sampling of themachine space is determined (1236). The solution quality and efficiencyof a sampling-based path planner depends on how well the planner samplesthe configuration space. Sampling with fine resolutions may result in amore optimal path but it also increases the computation time. In orderto achieve a balance between the performance and the path quality, astrategic and deterministic sampling method is used.

FIG. 13 depicts sampling of machine space for developing a positioningpath. The drawing depicts the sampling in 2D in order to facilitate thedescription. One of ordinary skill in the art will readily appreciatehow to apply the teachings to higher dimensions. Strategic anddeterministic sampling (1236) is performed by individual sampling ofeach axis of motion. Strategic regions surrounding relevant features ofa machining scene are identified for sampling. Sample configurations aretaken from the identified regions for each axis. These regionssurrounding relevant features of the machining scene may include regions1304 c, 1304 d surrounding start and goal configurations 1104, 1106,regions 1304 a, 1304 b surrounding optimal configurations 1108, 1110from a known positioning path, and regions 1304 e surrounding boundingboxes of scene objects, one of which 1302 is depicted in FIG. 13,including the workpiece, fixtures, setups clamps, holding devices,machine parts etc. These bounding boxes may be provided from thesimulation of the CNC machine and can be used to improve the samplingquality. Each axis of motion has a minimum and maximum value based onthe machine travel limits. The region between the axis minimum andmaximum is divided into different spans using locations corresponding tothe start and goal configurations. Sample configurations depicted asblack dots, one of which is referenced as 1306, are collected from theidentified regions. Each span is then checked to verify if it has beensampled by the strategic locations. More samples can be collected from aspan, if a large section of it has not been sampled. A minimum samplingresolution defines the minimum possible difference between the samplesalong each axis. The method determines if the sampling was successful(1238). If the axis cannot be sampled with the specified resolutionanymore (No at 1238), the sampling is declared unsuccessful and if thesamples cannot be sampled at a lower resolution, the process ends(1240). If the strategic and deterministic sampling (1236) did notsample the machine axis at the minimum sampling resolution, theresolution may be reduced and additional samples determined. Althoughthe above has described the use of deterministic sampling to obtainsamples from identified regions, it is contemplated that other samplingtechniques may be used. For example, random sampling of the machinespace may be used; however such sampling may result in the considerationof a larger number of samples and as such may require additionalcomputation time to determine the path.

If the sampling was successful (Yes at 1238), the collected samples 1306for each axis are used to build a search graph (1242). The locations ofthe collected samples on each axis are used to build a grid network ofsamples as a search graph. The grid network is built based on aneighborhood definition. In general a neighbor of a configuration Q canhave 1 to P coordinates differing from those of Q, where P is the spacedimension. For example in a 2D space (i.e. P=2) for a point Q, a totalof eight neighbors can be defined. Four of these neighbors have onecoordinate different from Q and the other four have two coordinatesdifferent from Q. Once the neighborhood is defined, the grid network ofsamples is created by connecting neighboring sampled locations. The gridnetwork is then provided as a search graph. The generated graph is thensearched using a discrete heuristic search method such as A* (1244). TheA* search finds a minimum cost path in the graph between start and goalconfigurations. The cost of the known solution is used in the A*algorithm as an upper bound for the solution. Thus, the A* algorithmbecomes faster by pruning out those nodes that would result in a moreexpensive path than the known solution.

The result of performing the graph search is either a path cheaper thanthe known solution or no path. The method determines if there is anypath through the graph provides a cheaper path than the initial path. Nopath may be found when all possible paths through the graph nodesbetween start and goal are more expensive than the known solution. Thismeans the sampling was not good enough to generate a better solutionthan the known solution. Therefore, if there are no cheaper paths (No at1246), more samples may be collected (1236) or attempted to becollected. The strategic sampling may be performed at the previouslyused sampling resolution, or the sampling resolution may be reduced. Atthis stage more samples are collected from non-sampled regions of eachspan along each axis, and if the sampling is successful, a new graph isbuilt including with the new samples (1242). Alternatively, the newsamples may be added to the existing graph. Once the A* algorithmidentifies a cheaper path than the previous solution, it needs to bechecked and verified (1248) by the simulation and verificationfunctionality. If the path is invalid (No at 1248), invalid pathsegments are identified and removed from the graph (1254). It isdetermined if the graph is exhausted (1256). If the graph is not able togenerate a path between start and goal anymore, it is declared exhausted(Yes at 1256) and processing returns to collect more samples (1236).Otherwise, the graph is not exhausted (No at 1256) and so the graph issearched (1244) to find the next minimum cost path. If the verificationreports no problems for the path (Yes at 1248), it is declared valid andthe method may determine if the path should be optimized further (1250).If the path is not to be optimized further (No at 1250) the positioningpath is returned (1258). If the path is to be optimized further (Yes at1250), the cost associated with the current positioning path is set asthe upper bound (1252) and new samples may be retrieved (1236) in anattempt to find an improved path.

FIG. 14 depicts developing the positioning path. The drawing depicts thepositioning paths in 2D in order to facilitate the description. One ofordinary skill in the art will readily appreciate how to apply theteachings to higher dimensions. A number of potential positioning pathsbetween the start configuration 1104 and the goal configuration 1106 aredepicted by dashed lines. Three potential positioning paths aredepicted. The first path 1402 may not provide a better positioning pathsince it may have a higher time-cost than the initial positioning path.Another potential path 1404 may provide a lower cost path; however, itmay not provide the lowest cost path of all the valid paths and as suchis not optimal. Another possible positioning path 1406 may provide thelowest cost path, however it is not valid as it violates constraintssince it requires the tool to move through the workpiece. Finally, thepath 1408 is valid since it does not violate any constrains and connectsthe start and goal configurations. The path 1408 also has a lower timecost associated with it than the initial positioning path and determinedpositioning path 1404 and as such it provides a better positioning paththan the initially determined path. The start and goal configurations1104, 1106 may be either initially received configurations, or may bethe start and goal configurations as adjusted based on optionallyspecified path customizations.

The above has described automatically generating an optimizedpositioning path by generating an initial positioning path using a fastdirectional search and minimization technique. The initial positioningpath may then be used to generate an optimized positioning path using adeterministic sampling based approach. Although the initial positioningpath may reduce the time required to generate the optimized positioningpath using the deterministic sampling based approach, it is notnecessary to have an initial positioning path. In such a case, the firstvalid positioning path found by the deterministic sampling basedapproach may be used as the upper bound on costs for optimizing thepositioning path.

FIG. 15 depicts a method for generating positioning path data for a CNCmachine. The method 1500 determines a start machine configuration and agoal machine configuration of a tool in a machine configuration space(1502). Determining the respective machine configurations may comprisetranslating a received tool location specified in a workpiece coordinatespace into the machine space. Further, the machine configurations may beadjusted based on optionally specified customizations of the paths. Themethod identifies respective regions surrounding one or more relevantfeatures of a machining scene (1504) in the machine configuration spacefor sampling of possible machine configurations and determines aplurality of possible machine configurations from each of the identifiedone or more regions in the machine configuration space (1506). Themethod determines a positioning path from the plurality of possiblemachine configurations that connects the start configuration to the goalconfiguration (1508). The path may be determined using varioustechniques including, for example, a heuristic graph searching techniquesuch as an A* search approach. Once a positioning path is determined,the method determines if the determined positioning path is valid usinga simulation of the CNC machine (1510). The simulation of the CNCmachine determines if the positioning path violates any machiningconstraints by simulating the path using the in process stock of theworkpiece and machine characteristics, including machine kinematics,machine axis travel velocities and acceleration limits, travellimitations for each control axis, positioning methodologies, workpiecesetup, location of machine components or fixtures, and location ofclamps. If the positioning path is valid, the method generatespositioning path data for moving the tool of the CNC machine along thedetermined positioning path (1512). The positioning path data maycomprise NC data, or may be specified in any other suitable format.

FIG. 16 depicts a system for machining a part. The system 1600 comprisesa CAD/CAM computing device 1602 that is used to specify the geometry ofthe part to be machined. The CAD/CAM device may be provided by a desktopcomputer or server or similar computing device. The CAD/CAM computingdevice 1602 may produce tool path information for machining the part.The tool path information is provided to an NC post-processor computingdevice 1606. The information may be provided over a network 1604, or maybe provided using transferable media or other types of communicationsuitable for transferring the information from the CAD/CAM computingdevice 1602 to the NC post-processor computing device 1606. Further,although depicted as being located on separate physical computers, it ispossible that the NC post-processor be provided on the same computer asthe CAD/CAM software. The NC post processor generates machine specificcode for controlling a particular CNC machine 1610, 1612. The machinespecific code may be specified as an NC program which may be provided tothe particular CNC machine over a network 1608 or other suitablecommunication means such as a transferrable media.

The NC post-processor may include position path planning functionality1616 for automatically generating positioning paths for machines basedon start and goal configurations and using a simulation of the machineas described above. Additionally, or alternatively, the CAD/CAMcomputing device 1602 may incorporate similar position path planningfunctionality 1614 for generating positioning paths as described abovewithin the CAD/CAM device. The NC post processor functionality may beincorporated into the CAD/CAM software in order to simplify thegeneration of the code for machining the part on a particular CNCmachine. As depicted, the automatic generation of the positioning pathallows specific code for different types of CNC machines 1610, 1612 tobe automatically generated without requiring additional input from theuser, other than specifying which CNC machine is to be used.Additionally, or alternatively, the CNC machines 1618, 1620, or moreparticularly the controllers of the CNC machines, may incorporatesimilar position path planning functionality 1618, 1620 for generatingpositioning paths as described above.

The above has described various particular embodiments with regard togenerating positioning paths for CNC machines 3, 4 or 5 axis. It iscontemplated that the same techniques as taught herein can be applied toother machining devices that incorporate further or additional degreesof freedom. For example, the positioning paths may be generated formachining a part on a CNC machine having 6 axes, or using a robotmachining device having more degrees of freedom.

Regardless of if the positioning path planning functionality isimplemented in the CAD/CAM computing device, the NC processor computingdevice or the controller of one of the CNC machines, the positioningpath planning functionality is provided by executing instructions storedin a memory using a processor of the respective computing device. Theinstructions when executed by the processor, configure the computingdevice to provide the positioning path planning functionality describedabove.

Although the description discloses example methods, systems andapparatus including, among other components, software executed onhardware, it should be noted that such methods and apparatus are merelyillustrative and should not be considered as limiting. For example, itis contemplated that these hardware and software components could beembodied exclusively in hardware, exclusively in software, exclusivelyin firmware, or in any combination of hardware, software, and/orfirmware. Further, the described functionality may be provided as codeor instructions stored on transitory or non-transitory media. Further,although certain components or apparatuses are depicted as a singlephysical component, it is contemplated that they could be implemented asmultiple separate components. Further still, it is contemplated that thefunctionality of multiple separate components described herein could beprovided in a single component. Accordingly, while the followingdescribes example systems, methods and apparatus, persons havingordinary skill in the art will readily appreciate that the examplesprovided are not the only way to implement such systems, methods andapparatus.

Although the present invention has been described in connection with oneor more preferred forms of practicing it, those of ordinary skill in theart will understand that many modifications can be made thereto withinthe scope of the claims that follow. Accordingly, it is not intendedthat the scope of the invention in any way be limited by the abovedescription.

What is claimed is:
 1. A method for generating positioning path data foran NC program for a computer numerically controlled (CNC) machine, themethod comprising: determining, by a computing device, a plurality ofpossible paths, each for repositioning a tool from a first configurationto a second configuration; determining, by the computing device, foreach of the plurality of possible paths if the respective possible pathis valid by simulating repositioning of the tool along the respectivepossible path using a simulation of the CNC machine; selecting, by thecomputing device, as a positioning path one of the plurality of possiblepaths determined to be valid; generating, at the computing device,positioning path data for moving the tool of the CNC machine along theselected positioning path; and generating, at the computing device, theNC program comprising the positioning path data for controlling aposition of the tool of the CNC machine; wherein each of the pluralityof possible paths is determined by: receiving, at the computing device,the first and the second configurations; adjusting, by the computingdevice, the first and second configurations; determining, by thecomputing device, a new first configuration using a disengage path fromthe adjusted′ first configuration and a new second configuration usingan engage path from the adjusted second configuration; and determining,by the computing device, a path between the new first configuration andthe new second configuration; wherein the first and secondconfigurations are adjusted based on at least workpiece proximity andwall detection to a minimum distance in a direction that does not causethe tool to be in contact with a workpiece.
 2. The method of claim 1,wherein each of the plurality of possible paths is determined to bevalid if the tool does not violate machining constraints duringrepositioning along the path in the simulation.
 3. The method of claim2, wherein violating the machining constraints comprises one or more of:contacting a workpiece with the tool; contacting a fixture with thetool; contacting a setup with the tool; contacting a holding device withthe tool; contacting a structure of the CNC machine with the tool; andcontacting or passing through an obstacle zone with the tool.
 4. Themethod of claim 2, wherein violating the machining constraints comprisesunacceptable interference between two or more of the tool, workpiece,fixture, setup, holding device, and structure of the CNC machine.
 5. Themethod of claim 2, wherein each of the plurality of possible paths isfurther determined to be valid if the simulation does not exceed definedCNC machine travel limits.
 6. The method of claim 1, wherein the minimumdistance is a user-selected length or automatically determined length.7. The method of claim 1, wherein the disengage path and the engage pathare based on a predefined strategy.
 8. The method of claim 7, whereinthe disengage path and the engage path are respectively along auser-defined direction from the adjusted first and secondconfigurations.
 9. The method of claim 7, wherein the disengage path andthe engage path are respectively along a tool axis direction from theadjusted first and second configurations.
 10. The method of claim 7,wherein the disengage path and the engage path are respectively alongthe direction of an axis of control of the CNC machine.
 11. The methodof claim 1, wherein the path between the new first configuration and thenew second configuration is determined using a sample-based approach.12. The method of claim 1, wherein simulating the repositioning of thetool comprises performing one or more of: a collision test, a traveltest, and a travelling time computation.
 13. The method of claim 12,wherein simulating the repositioning of the tool incorporates machinecharacteristics into simulating machining on the CNC machine, themachine characteristics comprising one or more of: machine kinematics;velocity limits; acceleration limits; travel limitations for eachmachine axis; positioning methodologies; workpiece setup; location ofmachine components or fixtures; and location of holding devices.
 14. Themethod of claim 12, wherein simulating the repositioning of the toolsimulates a dynamically changing workpiece.
 15. The method of claim 1,wherein generating the NC program comprises appending the generatedpositioning path data to the NC program.
 16. The method of claim 1,further comprising: receiving cutter location (CL) data comprising oneor more cutting paths each defining a respective path where the tool isin contact with the workpiece; generating NC data for the one or morecutting paths; and appending the NC data for the one or more cuttingpaths to the NC program.
 17. The method of claim 16, wherein thepositioning path is defined by any one of: the first configuration ofthe tool is a current configuration and the second configuration of thetool is a starting configuration of a cutting path; and the firstconfiguration of the tool is the current configuration and the secondconfiguration of the tool is an end configuration.
 18. A computingdevice for generating positioning path data for an NC program for acomputer numerically controlled (CNC) machine, the computing devicecomprising: a processor for executing instructions; and a memory forstoring instructions, which when executed by the processor configuresthe computing device to provide a method comprising: determining, by thecomputing device, a plurality of possible paths, each for repositioninga tool from a first configuration to a second configuration;determining, by the computing device, for each of the plurality ofpossible paths if the respective possible path is valid by simulatingrepositioning of the tool along the respective possible path using asimulation of the CNC machine; selecting, by the computing device, as apositioning path one of the plurality of possible paths determined to bevalid; generating, at the computing device, positioning path data formoving the tool of the CNC machine along the selected positioning path;and generating, at the computing device, the NC program comprising thepositioning path data for controlling a position of the tool of the CNCmachine; wherein each of the plurality of possible paths is determinedby: receiving, at the computing device, the first and the secondconfigurations; adjusting, by the computing device, the first and secondconfigurations; determining, by the computing device, a new firstconfiguration using a disengage path from the adjusted firstconfiguration and a new second configuration using an engage path fromthe adjusted second configuration; and determining, by the computingdevice, a path between the new first configuration and the new secondconfiguration; wherein the first and second configurations are adjustedbased on at least workpiece proximity and wall detection to a minimumdistance in a direction that does not cause the tool to be in contactwith a workpiece.
 19. A method for generating positioning path data foran NC program for a computer numerically controlled (CNC) machine, themethod comprising: determining, by a computing device, a plurality ofpossible paths, each for repositioning a tool from a first configurationto a second configuration; determining, by the computing device, foreach of the plurality of possible paths if the respective possible pathis valid by simulating repositioning of the tool along the respectivepossible path using a simulation of the CNC machine; selecting, by thecomputing device, as a positioning path one of the plurality of possiblepaths determined to be valid; generating, at the computing device,positioning path data for moving the tool of the CNC machine along theselected positioning path; and generating, at the computing device, theNC program comprising the positioning path data for controlling aposition of the tool of the CNC machine; wherein selecting thepositioning path comprises: determining a travel distance for each ofthe plurality of possible paths determined to be valid; determining atravel time using the determined travel distance for each of theplurality of possible paths determined to be valid; and selecting as thepositioning path the possible path having a shortest determined traveltime.